Pattern control apparatus for yarn feed



1968 i 'r. M. RHODES 3,395,659

PATTERN CONTROL APPARATUS FOR YARN FEED Filed Nov. 25, 1964 INVENTOR.

BYQMQ United States Patent 3,395,659 PATTERN CONTROL APPARATUS FOR YARN FEED Travis M. Rhodes, Box 71, Dalton, Ga. 30720 Filed Nov. 23, 1964, Ser. No. 412,957 6 Claims. (Cl. 11279) This invention relates to the pattern control apparatus for yarn feed and particularly to the use of removable inserts in the contours or notches in pattern bars or the like which may be used in conjunction with machines for tufting pile fabrics for producing patterned or tufted extiles having a variation in the height of the pile.

Machines for tufting wide backing material to form tufted textiles are well known and comprise generally a series of needles which move in association with the backing fabric to apply rows of looped pile which extends from the surface of the fabric. There are a number of ways in the art for delivering the pile yarn tothe needles or whatever implements are used for applying the yarn to the backing material. Yarn control or feed devices are shown in U.S. Letters Patents Numbers 2,853,032; 2,853,033; 2,853,034; 3,199,361 and other issued U.S. Letters Patents. The characteristic of all such machines is the use of some arrangement, such as pattern bars, that have spaces through which the yarn passes and the extent of the space affecting and controlling the amount of yarn which is delivered. In many instances one of the dimensions of the depression or notch determines the amount of yarn and when finished said depressions or notches are used, as in a pattern bar, the critical dimension determines the ultimate pattern which is made on the backing material. This is how so-called high-low loop designs are made and an infinite number of patterns may be designed and executed in this manner.

The members in the pattern control, such as a pattern bar, which have the slots, notches, or depressions in them for controlling the pattern are usually made of angle iron .or extruded aluminum and are expensive mainly because of the time and effort required to properly form the correct dimension in the depressions or notches therein. Therefore, a change in pattern is a costly operation and these factors contribute to the limitation on the range of pile height and the number of different patterns which are offered on the market.

A primary object of the present invention is to provide a different method for changing the pattern control apparatus on a machine.

Another object is to provide individual pattern adapters which may be of nylon or other suitable material and attachable on the pattern control to change the critical dimension and wherein said attachments may be of dif ferent colors easily recognizable and readily applied to follow a pre-prepared pattern diagram.

Another object .of the present invention in one embodiment is to provide permanently attached chains, slats or gears or other form of pattern control having spaces thereon with a permanent dimension representing the maximum pile level and then with provision for inserting or removing adapters which are positionable on the pattern control device and removable therefrom.

A further object of this invention is to provide individual adapters or inserts which may be manufactured from nylon or other suitable material and being of a varying dimension in one direction representing different yarn feed control for each insert. Furthermore, according to the foregoing object the inserts can be different colors representing a different pile height.

Other and further objects and advantages of my invention will become apparent upon reading the following 3,395,659 Patented Aug. 6, 1968 specification taken in conjunctionwith the accompanying drawings, in which:

FIG. 1 is an elevation view of a typical pattern control bar having inserts or adapters of the present invention positioned thereon.

FIG. 2 is an end elevation view of the pattern control bar and insert shown in FIG. 1.

FIG. 3 is an elevation view of a modified form of the pattern control bar having an insert thereon.

FIG. 4 is a top plan view of one of the inserts shown in FIG. 1.

FIG. 5 is an elevation view of the insert shown in FIG. 3.

FIG. 6 is a side elevation view of the adapter shown in FIG. 4.

FIG. 7 is a perspective view of the type of pattern bar shown in FIG. 3 having one of the adapters mounted thereon.

It is to be understood at the outset that the present adaptation and method for changing the pattern may be used on any machine which utilizes the apparatus or principle of controlling the yarn by means of a dimension of a pattern bar or similar apparatus which somehow cooperates to determine the amount of yarn fed through the size of that critical dimension. For example, as stated previously, in those machines mentioned in the prior U.S. patents which employ various pattern control devices, the present invention may be manufactured and applied thereto. Likewise, it may be applied to other machines and also to textile machines which do not necessarily utilize needles penetrating the backing of the material but in any instance where yarn is fed to a plurality of implements that apply the yarn to some use.

Thus, the pattern control bar 10 shown in FIG. 1 is typical and diagrammatic and does not in of itself form any modification or change in the art. In similar manner, the modified form of pattern bar shown in FIGS. 3 and 7 are typical of the art and do not in themselves undergo any modification in the present invention.

For purpose of explanation and description, it is to be understood that all such pattern bars, gears, chains, slats, bolts or other devices which are used as pattern control implements, such as 10 in FIG. 1, have notches, depressions, contours or recesses 12 therein which have what may be considered a critical dimension D shown in FIG. 1 such representing the length of the slot to the bottom of the slot 14. In accordance with what is well known in the art and described fully in the foregoing mentioned patents, variation of the depth D on such pattern control apparatus will result in feeding a different length of yarn thereby controlling the amount of yarn which is fed to the yarn applying implement such as needle thereby determining the ultimate pattern to be formed on the backing material which is modified on the machine. In those instances where the pattern control bar 10 is being used on the tufted needle machine of the sort common in the carpet industry, the pattern control bar 10 is provided with according to the prior art slats or other means for adapting and controlling the depth D to vary the pile height. As is well known in the art, and discussed previously, the changeover from one pattern to another can involve several thousand dollars in expense and the manufacturing processes necessary in the production of pattern control bars and other similar apparatus is quite significant.

In FIG. 1 there is shown two adapters of the present invention 16, 18, the main difference being that 18 is of shorter length dimension than 16 so that when applied to the pattern control bar as shown in FIG. 10 the dimension which presently may be known as depth from the top 20 of adapter 18 to the top edge of the pattern control bar 10 which is determined by the edges 22 of teeth 24, is greater than the comparable dimension above adapter 16 top 26 thus resulting in a variation in pile height from the two adapters 16 side by side which are identical to the one adapter 18 which is different.

Adapters 16, 18 are identical except for the critical dimension.

In FIG. 4 there is shown adapter or insert 16 which may be manufactured in one piece as by molding from nylon or any other suitable material of plastic or otherwise and in cross section to be somewhat in an I-shape having recesses 28 on a post faces and the opposite edges 30 of which are provided with serrations or notches to provide a compressible and rough friction surface to assist in holding the inserts in position in the notches 12 on the pattern bar in the manner shown clearly in FIG. 7.

The modified form shown in FIG. 3 does not present or represent any departure from the invention shown in FIG. 1 but merely is a different type of slat or pattern bar 40 which is well known in the art and to which the present adapters 16 or 18 may apply in the same manner as shown in FIG. 1. In FIG. 7 there is shown the pattern bar 40 of FIG. 3 having one of the longer adapters 16 applied thereto and across which is being fed a length of yarn 44 which leads from the yarn feed supply on the one side to the implement such as a needle on the machine. It is to be noted that the top surface 31 of the adapters 16 or 18 are formed with a slight concavity of smooth surfaces to assist the yarn 44 in remaining more in the center of the adapter 16 than at the edges to reduce any possibility of improper yarn feeding.

The present arrangement should enable any producer to eliminate the cost of cutting a new slat pattern for each new design and to reduce cost substantially. In any known pattern control arrangement, the permanent slats or pattern control bars may be modified through the use of the present adapter 16, 18 properly sized and fitted to that particular pattern control bar arrangement. A significant thing is the fact that the adapter 16, 18 or any other adapters made in accordance with this invention of any dimension may be manufactured from plastic or nylon or other material of different colors representing a different size adapter. For example, the pattern bar 10 itself would have the maximum D fixed into the pattern bar and this would not be changed in those instances where the pattern would call for the maximum feed. However, there could :be variations in height of any number although it is contemplated that perhaps there would be several stock sizes such as a half inch pile that could, be represented by a red color, a three eights inch pile that could be represented by a green color and a one quarter inch which could be represented by a blue color and smaller or larger dimension adapters 16, 18, for whatever power range is desired. Nylon is mentioned as a likely material because it can be made to the desired rigidity, it can be molded in mass production into different adapters 16, 18 of different sizes, it possesses good anti-friction characteristics and it has a somewhat of a lubricatedtype surface which would enable the yarn 44 to flow freely thereacross.

Once a desired pattern to be made has been designed, it can be reduced to written form by a template or a drawing showing the colors to be used to modify the pattern control bar or slat 10. Then, almost any competent employee with a little instruction can follow a diagram to remove the existing inserts 16 or 18 and then to replace the particular notches with the new pattern taking out inserts in some places and putting in other inserts to accomplish the desired pattern. Another extremely important advantage of the present invention is the fact that if something shows up in the pattern on the machine which was not contemplated by the pattern designer or if an objectionable apearance takes place when the pattern is executed initially on the machine then revisions can be made simply by replacing selected positions without redoing the entire pattern bar or having to remove the pattern bar and have expensive machine work done to correct the difificulty.

While I have shown and described a particular embodiment of my invention, and mentioned the invention in conjunction with existing machinery and well known types of devices, this by way of illustration only and as a means of disclosure and does not constitute any sort of limitation on the scope of my invention since various alterations, changes, deviations, eliminations, ramifications, substitutions, and revisions may be made in the embodiment shown and described without departing from the scope of my invention as defined in the appended claims.

I claim:

1. Ina pattern control comprising a plurality of notched pattern bars for feeding yarn to a machine and wherein many different yarns are fed simultaneously and controlled by said pattern control means which includes a plurality of yarn positions corresponding with the notches in the pattern bars each having a critical dimension representing the amount of yarn to be fed at that particular position, the improvement comprising:

(a) a plurality of individual adapter means selectively and remov-ably positioned in said notches at selected yarn positions to vary the significant dimension at those positions, at least one of said individual adapter means being of a different size than the other adapter means thereby affecting its respective yarn position differently than at least one other by varying said critical dimension thereby varying the amount of yarn fed between the differently affected yarn positions, whereby a different amount of yarn will be fed which controls the amount of yarn in the design at the respective locations in the fabric.

2. In a pattern control comprising a plurality of notched pattern bars for feeding yarn to a machine and wherein many different yarns are fed simultaneously and controlled by a pattern control means which includes a plurality of yarn positions corresponding with the notches in the pattern bars each having a critical dimension representing the amount of yarn to be fed :at that particular postion, the improvement comprising:

(a) a plurality of individual adapter means selectively positioned in more than one yarn position to vary the significant dimension at those positions, thereby to provide an adjustment in the yarn fed, at least one of said individual adapter means being of a different size than the other adapter means thereby affecting its respective yarn position differently than at least one other by varying said critical dimension thereby varying the amount of yarn fed between the differently affected yarn postions, whereby a different amount of yarn will be fed which controls the amount of yarn in the design at the respective location in the fabric.

3. In a pattern control comprising a plurality of notched pattern bars for feeding yarn to a machine and wherein many different yarns are fed simultaneously and controlled by a pattern control means which includes a plurality of yarn positions corresponding with the notches in the pattern bars each having a critical dimension representing the amount of yarn to be fed at that particular position, the improvement comprising:

(a) a plurality of removable adapters of plastic and the like removably attached in more than one yarn position to vary the significant dimension at those positions, at least one of said individual adapters being of a different size than some of the other adapters thereby affecting its respective yarn position differently than at least one other by varying said critical dimension thereby varying the amount of yarn fed between the differently affected yarn positions, whereby a different amount of yarn will be fed which controls the amount of yarn in the design at the respective locations in the fabric.

5 6 4. In a pattern control comprising a plurality of 6. The device in claim 4 wherein each of said adapters notched pattern bars for feeding yarn to a machine and is a block-like plastic member having grooves therein to wherein many difierent yarns are fed simultaneously and fit the pattern bars next to a respective notch therein. controlled by a pattern control means which includes a plurality of yarn positions corresponding with the notches 5 References Cit d in the pattern bars each having a critical dimension representing the amount of yarn to be fed at that particular UNITED STATES PATENTS position, the improvement comprising: 386,623 7/ 1888 y (a) a plurality of removable adapters inserted in and ,361 1/1964 Nowicki 11279.6 removable from the notch at each selected position 2,639,093 9/1954 a tt 61 al- -v 242-457 to vary the significant dimension therein, at least one 10 2,763,799 10/1956 Porter it a 242-157 of said individual adapters being of a difierent size 3,266,692 8/19 6 W itten 242-157 XR than some of the other adapters thereby affecting its respective yarn position difierently than at least one FOREIGN PATENTS other by varying said critical dimension thereby vary- 15 1 083 1 /19 2 Great Britain. ing the amount of yarn fed between the differently 377 014 7 1932 Great Britain affected yarn postions, whereby -a diiferent amount of yarn will be fed which controls the amount of yarn JORDAN FRANKLIN Primary Examiner in the design at the respective locations in the fabric. 5. The device in claim 4 wherein said adapters are dif- 20 I. R. BOLER, Assistant Examiner. ferent colors. 

1. IN A PATTERN CONTROL COMPRISING A PLURALITY OF NOTCHED PATTERN BARS FOR FEEDING YARN TO A MACHINE AND WHEREIN MANY DIFFERENT YARNS ARE FED SIMULTANEOUSLY AND CONTROLLED BY SAID PATTERN CONTROL MEANS WHICH INCLUDES A PLURALITY OF YARN POSITIONS CORRESPONDING WITH THE NOTCHES IN THE PATTERN BARS EACH HAVING A CRITICAL DIMENSION REPRESENTING THE AMOUNT OF YARN TO BE FED AT THAT PARTICULAR POSITION, THE IMPROVEMENT COMPRISING: (A) A PLURALITY OF INDIVIDUAL ADAPTER MEANS SELECTIVELY AND REMOVABLY POSITIONED IN SAID NOTCHES AT SELECTED YARN POSITIONS TO VARY THE SIGNIFICANT DIMENSION AT THOSE POSITIONS, AT LEAST ONE OF SAID INDIVIDUAL ADAPTER MEANS BEING OF A DIFFERENT SIZE THAN THE OTHER ADAPTER MEANS THEREBY AFFECTING ITS RESPECTIVE YARN POSITION DIFFERENTLY THAN AT LEAST ONE OTHER BY VARYING SAID CRITICAL DIMENSION THEREBY VARYING THE AMOUNT OF YARN FED BETWEEN THE DIFFERENTLY AFFECTED YARN POSITIONS, WHEREBY A DIFFERENT AMOUNT OF YARN WILL BE FED WHICH CONTROLS THE AMOUNT OF YARN IN THE DESIGN AT THE RESPECTIVE LOCATIONS IN THE FABRIC. 